Table Of ContentModeling, Sensing and Control of
Gas Metal Arc Welding
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Modeling, Sensing and Control of
Gas Metal Arc Welding
Desineni Subbaram Naidu
Idaho State University
Idaho, USA
Selahattin Ozcelik
Texas A&M University
Texas, USA
Kevin L. Moore
Utah State University
Utah, USA
2003
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Dedicated to
Herschell B. Smartt
for introducing this research topic to us.
Authors
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Vll
PREFACE
Arc welding is one of the key processes in industrial manufacturing.
It is believed that in the entire metal fabrication industry, arc welding
is the third largest job category behind assembly and machining. In
particular, two types of processes, gas metal arc welding (GMAW)
and gas tungsten arc welding (GTAW), are extensively used in factory
automation. The practice of industrial welding is heavily dependent
on the knowledge and vast experience of the welder, and, as such, at
present it is more an art than science. However, in order to make the
welding process more automated and less human (welder) dependent,
in the last two decades significant efforts have been made to introduce
the ideas of feedback in order to control the welding process to achieve
a good weld. Modeling a welding process is one of the most important
ingredients for controlling the process. Various modeling techniques
and automatic control strategies have been suggested to improve the
welding process.
In this research monograph we provide a survey of modeling, sens-
ing, and automatic control of the GMAW process. As such, this volume
is intended to be one of survey-oriented rather than a detailed account
of the subject matter. Further, the references under each chapter are
listed chronologically so that one can see the development of the field
over the years. To date, it appears that there have been at least three
related literature surveys: one in 1988 on expert robotic welding systems
(Sicard and Levine 1988), another in 1989 on sensory feedback control
for robotic arc welding (Cook 1983a), and a third tutorial type of survey
in 1989(Cook et al. 1989a). The first two focused on only robotic weld-
ing, while the third considered modeling, sensing and automatic control
of the GMAW process. The main purpose of the present monograph
is to provide researchers with an updated status of the state-of-the-art
in the areas of modeling, sensing and automatic control of the GMAW
welding process. In addition to survey, this monograph also collects
a number of original research results on this topic by the authors and
their colleagues.
This volume is composed of 6 chapters. After introducing some
preliminary classification of various welding processes in Chapter 1, the
modeling aspects GMAW process is briefly discussed in Chapter 2. The
viii
topics reviewed are physics of welding, metal transfer characteristics,
weld pool geometry, process voltages and variables, power supplies, etc.
The topic of sensing is reviewed in Chapter 3 touching upon various
sensors for arc length, weld penetration control, weld pool geometry,
and optical and intelligent sensors. The main theme of control is dealt
with in Chapter 4 starting from the classical control techniques of PI,
PID, multivariable control, adaptive control, and intelligent control.
A special feature of this book is in Chapter 5 where a case study is
presented by the authors and their students at Idaho State University
(ISU), Pocatello, Idaho in collaboration with the researchers at the
Idaho National Engineering and Environmental Laboratory (INEEL).
A brief epilogue draws the curtain on this book. A distinguishing
feature of this book is the survey on the literature arranged section-
wise at the end of each chapter for the convenience of the reader and a
final bibliography at the end of the book for general reference on this
research topic.
Desineni Subbaram Naidu
Pocatello, Idaho
Selahattin Ozcelik
Kingsville, Texas
Kevin L. Moore
Logan, Utah
April 2003
ix
Acknowledgments
We would like to take this opportunity to express our sincere thanks to
Dr.Herschell B.Smartt of the Idaho National Engineering and Environmental Lab-
oratory (INEEL) in Idaho Falls, Idaho for his encouragement of this research ac-
tivity. We particularly acknowledge his financial support, administered through
Associated Western Universities (AWU), Salt Lake City, Utah, during the summer
of 1997. We also acknowledge the support of INEEL through the University Re-
search Consortium-funded project, Advanced Control Welding Technology, which
stimulated the interest and need for the present research survey. We would also
like to thank the entire URC project team, including Lyndon Brown, Bob Yender,
Justin Tyler, Martin Murillo, Hardev Singh, Anna Mathews, and Mohamed Ab-
delrahaman. We also thank the College of Engineering at Idaho State University
(ISU), which provided facilities for the URC project and for the preparation of this
mongoraph. A special word of appreciation is also extended to our technical editor,
Ms. Leonora Schaelling.
Due to the nature of this survey-oriented project, we depended a lot on the
services of ISU Eli M. Oboler Library. In particular, the interlibrary loan staff,
Nancy and Joan, deserve special mention for their ungrudging cooperation and
timely action in bringing several of the copies of the references needed for the book
and for their additional enthusiasm in getting the whole volume when only one
particular article was requested! Also, our secretarial assistant Ann for doing lot of
copying.
For preparing the final copy of this book, we used our favourite I~TF~ format
in PCTEX321 Version 4.0. The figures were drawn mainly using CorelDRAW2and
exported into I_4TF~document.
Finally, this survey-oriented book project would have taken a lot more time
on our part, but for Subbaram's wife Sita, who had lot of patience in typing the
huge bibliography files used in this survey. Thanks Sita! Finally, we enjoyed every
moment of doing this project!
Desineni Subbaram Naidu
Pocatello, Idaho
Selahattin Ozcelik
Kingsville, Texas
Kevin L. Moore
Logan, Utah
1PCTEX32 and I_4~are trademarks of Personal TF~, Inc., Mill Valley, CA.
2CoreIDRAW is a registered trademarks of Corel Corporation.
